Modular Blow Mold System for Blow Molding a Container

ABSTRACT

A modular system for blow molding a container. The system may include a first portion, a second portion, and a third portion. The first portion and second portion may each include a shell, a mold removably coupled to the shell, and a top plate. The third portion may include a base and a base mold. The molds may be 3D printed. The molds together may define a blow mold cavity. The modular system may be used at lab scale, pilot scale, or full production scale. The molds may be durable and smooth enough for full production scale. Some embodiments are directed to methods for making a modular system for blow molding a container.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.16/932,151, filed Jul. 17, 2020, which is incorporated herein byreference in its entirety.

BACKGROUND

The present disclosure relates to blow systems for blow molding acontainer. More particularly, the embodiments relate to a modular systemfor blow molding a container and methods for making the same.

BRIEF SUMMARY

Some embodiments are directed to a modular system for blow molding acontainer comprising a first portion, a second portion, and a thirdportion. The first portion may comprise a first shell, a first moldremovably coupled to the first shell, a first top plate removablycoupled to the first shell, and a first filler material disposed in avolume defined by the first shell, the first mold, and the first topplate. The second portion may comprise a second shell, a second moldremovably coupled to the second shell, a second top plate removablycoupled to the second shell, and a second filler material disposed in avolume defined by the second shell, the second mold, and the second topplate. The first mold and second mold may be 3D printed. The thirdportion may comprise a base and a base mold. The base may be removablycoupled to the first shell and the second shell. The first mold, secondmold, and the base mold together may define a blow mold cavity when thefirst portion is coupled to the second portion.

In any of the various embodiments disclosed herein, the system furthercomprises a first cavity retainer removably coupled to the first shell,and a second cavity retainer removably coupled to the second shell.

In any of the various embodiments disclosed herein, each of the firstmold, the second mold, and the base mold is 3D printed.

In any of the various embodiments disclosed herein, the first shell, thefirst top plate, the second shell, and the second top plate are made ofCNC machined metal.

In any of the various embodiments disclosed herein, each of the firstmold, the second mold, and the base mold is isotropic.

In any of the various embodiments disclosed herein, the filler materialhas an elastic modulus of at least 6300 MPa.

In any of the various embodiments disclosed herein, the first mold, thesecond mold, and the base mold are made of a polymer comprising cyanateester.

In any of the various embodiments disclosed herein, the system furthercomprises at least one cooling channel within each of the first mold andthe second mold.

In any of the various embodiments disclosed herein, the system furthercomprises a locking ring removably coupled to the first shell. In any ofthe various embodiments disclosed herein, the base is configured toreleasably engage with the locking ring to secure the third portion.

In any of the various embodiments disclosed herein, the system furthercomprises a plurality of vertically aligned recesses configured toreceive the locking ring such that the vertical position of the thirdportion may be adjusted.

In any of the various embodiments disclosed herein, the first shell, thefirst top plate, the second shell, and the second top plate are made ofCNC machined metal.

Some embodiments are directed to an interchangeable mold for blowmolding a container. The mold may comprise a first 3D printed moldportion, a second 3D printed mold portion, and a 3D printed baseportion. The first 3D printed mold portion, the second 3D printed moldportion, and the 3D printed base mold portion together may define a blowmold cavity. The first 3D printed mold portion, the second 3D printedmold portion, and the 3D printed base portion may be isotropic. Thefirst 3D printed mold portion, the second 3D printed mold portion, andthe 3D printed base portion are configured to engage with a shell, theshell being compatible with a blow mold system to form blow-moldedcontainers within the blow mold cavity.

In any of the various embodiments disclosed herein, the first fillerportion comprises a first side configured to mate with a back of thefirst 3D printed mold portion and a second side configured to mate withan interior side of the shell. In any of the various embodimentsdiscloses herein, the second filler portion comprises a first sideconfigured to mate with a back of the second 3D printed mold portion anda second side configured to mate with the interior side of the shell.

In any of the various embodiments disclosed herein, the first 3D printedmold portion, the second 3D printed mold portion, and the 3D printedbase mold portion are made of a polymer comprising cyanate ester.

In any of the various embodiments disclosed herein, the mold furthercomprises a first filler portion and a second filler portion. In any ofthe various embodiments disclosed herein, the first filler portion has afirst side in contact with a back of the first 3D printed mold portionand a second side configured to contact an interior side of the shelland the second filler portion has a first side in contact with a back ofthe second 3D printed mold portion and a second side configured tocontact the interior side of the shell.

In any of the various embodiments disclosed herein, the first fillermaterial and the second filler material are both a plaster.

In any of the various embodiments disclosed herein, the first moldportion and the second mold portion each comprise cooling channels.

In any of the various embodiments disclosed herein, the mold furthercomprises a first cavity retainer and a second cavity retainer forsecuring the first filler portion and the second filler portion,respectively.

In any of the various embodiments disclosed herein, the mold furthercomprises a first cavity retainer and a second cavity retainer forsecuring the first filler portion and the second filler portion,respectively.

Some embodiments are directed to methods of making a modular blow moldsystem comprising 3D printing a first mold portion, a second moldportion, and a base portion; coupling the first mold portion to a firstshell to form a first half, the first half comprising a first volumedefined by the first mold portion and the first shell; coupling thesecond mold portion to a second shell to form a second half, the secondhalf comprising a second volume defined by the second mold portion andthe second shell; pouring a filler material in the first volume; pouringthe filler material in the second volume; and cooling the fillermaterial for form a solid filler.

In any of the various embodiments disclosed herein, the first moldportion, the second mold portion, and the base portion are made of apolymer comprising cyanate ester.

In any of the various embodiments disclosed herein, the filler materialcomprises a plaster.

In any of the various embodiments disclosed herein, the plaster is aliquid before the cooling.

In any of the various embodiments disclosed herein, the coolingcomprises cooling the filler material at room temperature.

In any of the various embodiments disclosed herein, the 3D printing stepcomprises forming at least one channel in the first mold portion and thesecond mold portion.

In any of the various embodiments disclosed herein, the method furthercomprises coupling the first half and the second half to form a blowmold comprising a blow mold cavity defined by the first mold portion andthe second mold portion.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a half of a modular blow mold system coupled to a baseportion.

FIG. 2 shows the assembled modular blow mold system of FIG. 1.

FIG. 3 shows an exploded view of the half of the modular system and baseportion of FIG. 1.

FIG. 4 shows a cross-sectional view of the half of the modular system ofFIG. 1 with a filler material taken alone line 4-4 of FIG. 1.

FIG. 5 shows a cross-sectional view of the half of the modular system ofFIG. 1 taken along line 5-5 of FIG. 1.

FIG. 6 shows a flow chart illustrating methods of assembling the modularblow mold system of FIGS. 1-5.

FIG. 7 shows a flow chart illustrating methods of making the modularblow mold system of FIGS. 1-5.

DETAILED DESCRIPTION

Some blow mold systems (e.g., shell mold, hot-fill mold, full-body mold,and small-cavity mold) use components generated using CAD(computer-aided design)/CAM (computer-aided manufacturing) systems.These systems may use laser engraving or etching for complex designfeatures. These systems can be expensive and require a significantamount of time to manufacture after design. These systems may be used tomake beverage containers using a blow mold process that involves placinga preform in a mold. The preform is heated, and then air is blown intothe preform to blow the heated preform material to form a containermatching the shape of the mold.

But developing a new container design can be an iterative process. Thisdesign process may involve creating multiple new molds as the design isconceived, developed, and refined. Accommodating this iterative processcan be a long and expensive process for existing blow mold systems. Andthe time required to produce the next iteration can delay the productioncycle such that multiple iterations may not be economically feasible.Accordingly, with existing blow mold systems, costs and time may preventmore than one or two molds from being produced before a full-scaleproduction model is produced.

Although attempts have been made to use 3D printing in blow moldsystems, these existing systems are suitable only for lab-scaleprocesses, produce poor surface quality, and have low strength thatresults in a short life cycle—typically capable of producing only a fewhundred bottles before failure. This low strength and poor surfacequality makes these systems suitable only for small scale production ata very early stage for consumer or machine testing. And the existing 3Dprinting for blow mold systems uses additive technology and materialslike acrylonitrile butadiene styrene (“ABS”) for producing polymer-basedcomponents. But the additive technology used results in molds thatproduce containers with poor surface quality. Because of these issues,these 3D printed mold systems are not suitable for scaling up beyondlab-scale processes. Thus, existing 3D printed mold systems aregenerally suitable for low-quantity runs during early design testing.

Accordingly, there is a need for a 3D printed blow mold system that iscost-effective, improves surface quality of the resulting containers,can withstand high temperature and high pressure, and is durable enoughto be used reliably for larger scale applications (e.g., pilot scale orfull production scale). Further, there is a need for a system with theseadvantages that is also modular, interchangeable, and able to beintegrated into existing production lines.

Using the blow mold systems according to embodiments disclosed herein,it is possible to produce a modular blow mold system that reducestooling costs and minimizes lead time on each container design and eachiteration of the design process. Further, the blow mold systemsdisclosed herein can be used in pilot scale and production scaleprocesses. Further, embodiments disclosed herein include interchangeablemolds so that portions of the blow mold system can be reused each time anew bottle design is used. These mold systems have improved strength,flexibility, and surface quality while also enabling repetitiveprototyping for new bottle design.

The modularity of the disclosed systems also allows the systems (e.g.,modular blow mold system 100) to accommodate a variety of bottle sizesand concepts to provide rapid switching of designs before a final designis locked in. Additionally, the mold systems disclosed herein arecapable of producing bottles with a surface quality sufficient for pilotscale or even full production scale, which can have the capability toproduce millions of bottles. And the same system (e.g., modular blowmold system 100) can be used across different platforms, from lab-scaleall the way to full production scale.

All of these benefits can result in accelerated production times andblow mold systems that are much more flexible. For example, after a newcontainer has been designed, a new mold may be ready for use within 1 to2 weeks, compared to 4 to 5 weeks for existing systems. And costs toproduce each mold may be reduced by as much as 80% to 90%.

As shown throughout the figures, modular blow mold system 100 mayinclude first portion 105, second portion 110, and base 115. In someembodiments, first portion 105 and second portion 110 are mirror imagesof one another (possibly with differences within the mold cavitydepending on the bottle design). Some embodiments disclosed herein arediscussed with reference to first portion 105, but it is to beunderstood that all discussion of first portion 105 applies to secondportion 110. For example, all components present in first portion 105may have a corresponding component on second portion 110, and secondportion 110 may have the same functionality as first portion 105.

FIG. 1 illustrates first portion 105 of modular blow mold system 100coupled to base portion 900. First portion 105 may include outer shell200, mold portion 300, retainer plates 400, top plate 500, cavityretainer 700, and locking ring 800 (see, e.g., FIG. 3). Second portion110 may include corresponding parts (e.g., outer shell 210 and top plate510 shown in FIG. 2 and a mold portion, retainer plates, a cavityretainer, and a locking ring). Base 115 may include base portion 900 andbase mold portion 310.

FIG. 2 illustrates modular blow mold system 100 when first portion 105,second portion 110, and base 115 are assembled. When assembled, as shownin FIG. 2, mold portions (e.g., mold portion 300 and base mold portion310) form an opening 1000 and a blow mold cavity inside of modular blowmold system 100. Opening 1000 may be sized to receive a preform (e.g.,preform 1200, see FIG. 4). The blow mold cavity may correspond to theshape of the containers to be blow molded.

FIG. 3 shows an exploded view of first portion 105 of modular blow moldsystem 100. Each of these components are discussed in detail below. FIG.4 illustrates a cross-sectional view of first portion 105, base moldportion 310, and base portion 900, of modular blow mold system 100 takenalong line 4-4 shown in FIG. 1. FIG. 5 illustrates a cross-sectionalview of first portion 105, base mold portion 310, and base portion 900,of modular blow mold system 100 taken along line 5-5.

A benefit of the disclosed system is the versatility of the system.Modular blow mold systems disclosed herein (e.g., modular blow moldsystem 100) may be able to accommodate any variety of container shape orsize but also be compatible with existing blow mold systems. Forexample, modular blow mold system 100, when assembled, may be the samesize as traditional blow mold systems. Additionally, modular blow moldsystem 100 may be used at lab scale, pilot scale, or full productionscale.

The modular systems (e.g., modular blow mold system 100) disclosedherein also improve flexibility. For example, certain components may bereused regardless of the shape or size of the container mold. Forexample, outer shells 200 and 210, retainer plates (e.g., retainerplates 400), top plates 500 and 510, locking rings (e.g., locking ring800), and base portion 900 may be reusable components. These reusablecomponents may be made of metal. In some embodiments, the reusablecomponents are computer numerical control (“CNC”) machined metal.

Other components, such as the mold portions (e.g., mold portion 300 andbase mold portion 310) and the cavity retainers (e.g., cavity retainer700) may be interchangeable. The interchangeable components may becompatible with the reusable components. For example, the mold portions(e.g., mold portion 300) and base mold portion 310 together may form amold corresponding to a bottle shape. Any bottle shape may be made bysimply replacing the mold portions (e.g., mold portion 300 and base moldportion 310) with different molds that are compatible with the reusablecomponents. In some embodiments, the interchangeable components are 3Dprinted using a polymer. For example, the interchangeable components maybe 3D printed using cyanate ester. In some embodiments, theinterchangeable components are 3D printed using a metal. For example,the interchangeable components may be made of a 3D printed aluminumalloy, bronze alloy, or stainless steel. The 3D printed components maybe fully isotropic. Unlike layered 3D printing methods, which can causea point of failure at each layer, fully isotropic components mayincrease strength and surface quality. As used herein, “isotropic”refers to a material in which the mechanical and thermal properties arethe same in all material directions (e.g., elastic modulus, compressivestrength). After 3D printing, the interchangeable components may befurther processed. In some embodiments, the interchangeable componentsare washed and cured in a temperature controlled chamber.

Outer shell 200 may have a mold contacting surface 203, a top platecontacting surface 204, an inner surface 205, and an outer surface 206.Outer shell 200 may also have recesses 201 and recesses 202.

Mold portion 300 may include container mold 302 and flanges 303. Flanges303 may contact with mold contacting surface 203 on outer shell 200.Screws may be used to secure mold portion 300 to outer shell 200 whereflanges 303 and mold contacting surface 203 meet. When mold portion 300is coupled to outer shell 200, a space is formed between inner surface205 and container mold 302. Container mold 302 may be acontainer-specific shape, and may be redesigned as needed to accommodatedifferent container designs and sizes. The shape and size of theportions of flanges 303 that contact mold contacting surface 203 mayremain the same even as container mold 302 is adjusted in size andshape. This allows mold portion 300 to easily engage with outer shell200. In some embodiments, retainer plates 400 and top plate 500 are usedto secure mold portion 300 to outer shell 200. For example, retainerplates 400 may be placed over flanges 303, and screws may be used tosecure outer shell 200, mold portion 300, and retainer plates 400together. Then top plate may be secured using screws 501.

Top plate 500 may be shaped to seat at top plate contacting surface 204of outer shell 200. Top plate 500 may be coupled to outer shell 200using screws. Outer shell 200, mold portion 300, and top plate 500together form volume 1100 (see, e.g., FIGS. 4 and 5). In someembodiments, volume 1100 remains empty during use. In some embodiments,a filler is used to fill volume 1100. For example, the filler may befiller material 600, discussed in more detail below.

Cavity retainer 700 may be positioned to enclose volume 1100 (and securefiller material 600 within volume 1100 in embodiments where fillermaterial 600 is used). For example, cavity retainer 700 may be coupledto outer shell 200. In some embodiments, cavity retainer 700 includesflanges 701 that mate with corresponding recesses 201. Locking ring 800may be coupled to outer shell 200. When coupled, locking ring 800engages with one of recesses 202 and provides a way to couple base moldportion 310 and base portion 900 to the first portion 105. Cavityretainer 700 and locking ring 800 may be moved up or down to accommodatemolds for containers with different heights. For example, for shortercontainers, cavity retainer 700 and locking ring 800 may couple usingtopmost recesses 201 and 202, respectively.

In some embodiments, second portion 110 has the same parts as firstportion 105. In some embodiments, all of the component parts of secondportion 110 are mirror images of the corresponding part of first portion105. For example, second portion 110 may include outer shell 210 and topplate 510 and a mold portion, retainer plates, a filler material, acavity retainer, and a locking ring that are mirror images of outershell 200, mold portion 300, retainer plates 400, top plate 500, fillermaterial 600, cavity retainer 700, and locking ring 800, respectively.In some embodiments, second portion 110 is a mirror image of firstportions 110 except for differences within the mold cavity depending onthe bottle design. Second portion 110 may couple to first portion 105and base 115.

Base 115 of modular blow mold system 100 may include base portion 900and base mold portion 310. Base mold portion 310 may be a moldcorresponding to the base of a container. Base mold portion 310 may beinterchangeable based on the desired container base shape. Base moldportion 310 may couple to base portion 900 using pins (e.g., pins 311)to form base 115. Base 115 may be coupled to first portion 105 andsecond portion 110 to form modular blow mold system 100. When firstportion 105, second portion 110, and base 115 are coupled, the moldportions (e.g., mold portions 300 and base mold portion 310) form a blowmold cavity that corresponds to the shape of a container.

Blow mold system 100 may include opening 1000. In some embodiments,opening 1000 is configured to receive a preform for a container (e.g.,preform 1200), as illustrated in FIG. 4. The preform may be a standardpreform for making a blow mold container. The preform may be made of anyvariety of blow moldable plastic (e.g., PET).

Mold portions (e.g., mold portion 300 and base mold portion 310) andcavity retainers (e.g., cavity retainer 700) may be made of any suitable3D printed material. To improve stability and thermal properties of themold, the 3D printed materials may have a high elastic modulus and highheat deflection temperatures while also providing a surface that issmooth and durable enough to provide consistent high-quality containersurfaces. The mold portions (e.g., mold portions 300 and base moldportion 310) may be made of material having a tensile strength of atleast 50 MPa (e.g., at least 75 MPa or at least 90 MPa), an elasticmodulus of at least 2500 MPa (e.g., at least 3000 MPa or at least 3500MPa), and a heat deflection temperature of at least 200° C. (e.g., atleast 225° C. or at least 250° C.). In some embodiments, the 3D printedmaterial is cyanate ester. In some embodiments, the 3D printed materialis a metal. In some embodiments, the mold portions (e.g., mold portions300 and base mold portion 310) and cavity retainers (e.g., cavityretainer 700) are made of the same material. In some embodiments, themold portions (e.g., mold portions 300) are made of a different materialthan base mold portion 310. For example, the 3D printed material may bea polymer or a metal. In some embodiments, the 3D printed material iscyanate ester.

Filler material 600 may further increase the strength of modular blowmold system 100. During the blow molding process, the molds aresubjected to pressure from within the blow mold cavity. Existing systemsused molds made of metal (e.g., steel) that can withstand pressurechanges or 3D printed molds that were prone to deflect or compressduring blow molding, which reduced the overall life and quality of themolds. Embodiments disclosed herein use strong 3D printed material(e.g., isotropic materials discussed above) to withstand the pressure. Afiller material (e.g., filler material 600) may further improve thestrength of the molds because the filler material is relativelyincompressible and helps the mold support the internal pressures withoutdeflecting.

In some embodiments, filler material 600 also improves the thermalproperties of modular blow mold system 100. Filler material 600 may be apourable plaster that is poured into volume 1100. Filler material mayhave a high elastic modulus and high compressive strength. Afterpouring, filler material 600 may solidify. In some embodiments, fillermaterial 600 is a plaster having a density of between 900 kg/m³ and 1500kg/m³. In some embodiments, filler material 600 is a plaster having adensity of about 1200 kg/m³. Filler material 600 may have an elasticmodulus. In some embodiments, filler material 600 may have an elasticmodulus of at least 5600 MPa (e.g., at least 6300 MPa, at least 7000MPa). In some embodiments, filler material 600 has an elastic modulus ofbetween 5600 MPA and 8400 MPa (e.g., between 6300 MPa and 7700 MPa). Insome embodiments, filler material 600 has an elastic modulus of about7000 MP a.

Regulating temperature and may be beneficial during blow molding becauseoperating conditions may involve elevated temperatures. For example, insome embodiments, the temperature of the mold portions (e.g., moldportions 300 or base mold portion 310) may be regulated by includingoptional internal cooling channels to improve cooling efficiency. Insome embodiments, each mold portion (e.g., mold portion 300) includes atleast one cooling channel (e.g., channels 301). In some embodiments moldportions (e.g., mold portion 300) includes at least three coolingchannels (e.g., cooling channels 301) that are configured to receive acooling fluid. In some embodiments, cooling channels (e.g., channels301) are vertically oriented conformal cooling channels, as shown by thecross-section shown in FIG. 5. In use, a gas or a liquid may be flowedthrough the cooling channels to improve cooling of the mold portions(e.g., mold portion 300). In some embodiments, a coolant is flowedthrough the cooling channels. In some embodiments, flowing a coolantthrough the cooling channels improves the productivity of blow moldsystem 100.

Modular blow mold systems disclosed herein (e.g., modular blow moldsystem 100) may be durable enough to be used at pilot scale and have alife cycle of at least 5000 containers (e.g., at least 7500 containers,at least 10,000 containers, at least 15,000 containers). In someembodiment modular blow mold system 100 is durable enough to be used atproduction scale and have a life cycle of at least 100,000 containers(e.g., at least 250,000 containers, at least 500,000 containers, atleast 1,000,000 containers, or at least 2,000,000 containers).

Modular blow mold system 100 may be readily assembled and disassembled.The steps of assembling blow mold system 100 are illustrated by the flowchart in FIG. 6. First portion 105 may be assembled at step 3000 through3400. At step 3000, mold portion 300 is positioned so that flanges 303of mold portion 300 align with mold contacting surfaces 203 of outershell 200. Then at step 3100, retainer plates 400 are positioned overflanges 303 of mold portion 300. Screws may be used to couple the outershell 200, mold portion 300, and retainer plates 400. At step 3200, topplate 500 is then fastened to outer shell 200 using screws at top platecontacting surface 204. Locking ring 800 is then coupled to outer shell200 at one of the recesses 202. The position of locking ring 800 may beadjusted depending on the height of the container to be blow molded. Ifa filler material is used, the filler may be made at optional step 3300.A method for making filler material 600 is discussed in detail below atstep 4200. In some embodiments, a filler material is not used. At step3400, cavity retainer 700 is coupled to outer shell 200 at recesses 202.Steps 3000 through 3400 may be repeated to assemble second portion 110.

At step 3500, base mold portion 310 may be coupled to base portion 900to form base 115. Then at step 3600, base 115 is coupled first portion105 by locking ring 800. After base portion 900 is coupled to firstportion 105 second portion 110 may be coupled to first portion 105 toform an assembled modular blow mold system 100 at step 3700. Once firstportion 105 and second portion 110 are coupled, the modular blow moldsystem 100 forms a blow mold cavity defined by each of the mold portions(e.g., mold portions 300 and base mold portion 310).

The components of modular blow mold system may be made using variousmethods. For example, at step 4000 the reusable components may be madeof metal using CNC machining. The reusable components may include outershells 200 and 210, pairs of cavity retainer plates (e.g., retainerplates 400), top plates 500 and 510, locking rings (e.g., locking ring800), and base portion 900. At step 4100, the interchangeable components(e.g., mold portions, 300, base mold portion 310, and cavity retainers700) may be made using 3D printing methods. In some embodiments, theinterchangeable components are made of a polymer (e.g., cyanate ester).In some embodiments, the interchangeable components are made of a metal.For example, the interchangeable components may be made of a 3D printedaluminum alloy, a bronze alloy, or stainless steel.

At step 4200, the filler material 600 may be formed. Forming fillermaterial 600 may include first coupling outer shell 200, mold portion300, retainer plates 400, and top plate 500, as discussed in steps 3000to 3300 above. Once those pieces are assembled, the assembled pieces maybe inverted so that top plate 500 is oriented down. Liquid fillermaterial 600 may then be poured into volume 1100 defined by outer shell200, mold portion 300, and top plate 500. In some embodiments liquidfiller material 600 is poured until volume 1100 is filled. After volume1100 is filled, liquid filler material 600 may be allowed to form asolid (e.g., to cure). For example, the filler material may be allowedto cool naturally (e.g., in room-temperature conditions) during which itwill naturally cure by transitioning into solid form. In someembodiments, the curing may take place in a temperature controlledchamber (e.g., an oven). In some embodiments, filler material 600 is aliquid plaster that transitions to (e.g., is cured to form) a solid(e.g., cured) plaster. In some embodiments, the filler material is notcured at elevated temperatures but is allowed to cool at roomtemperature.

As used herein, the terms “top,” “inner,” “outer,” and the like areintended to assist in understanding of embodiments of the disclosurewith reference to the accompanying drawings with respect to theorientation of the beverage closure as shown, and are not intended to belimiting to the scope of the disclosure or to limit the disclosure scopeto the embodiments depicted in the Figures. The directional terms areused for convenience of description and it is understood that a closureand a container may be positioned in any of various orientations.

As used herein, the term “3D printing” refers to a method of creating aphysical object using a digital model by joining or solidifying theprinted material into the shape of the physical object.

As used herein, when the term “about” is used in describing a value oran end-point of a range, the disclosure should be understood to includethe specific value or end-point referred to. Whether or not a numericalvalue or end-point of a range recites “about,” the numerical value orend-point is intended to include two embodiments: one modified by“about,” and one not modified by “about.” As used herein, the term“about” may include ±10%.

It is to be appreciated that the Detailed Description section, and notthe Summary and Abstract sections, is intended to be used to interpretthe claims. The Summary and Abstract sections may set forth one or morebut not all exemplary embodiments of the present disclosure ascontemplated by the inventor(s), and thus, are not intended to limit thepresent disclosure and the appended claims in any way.

The present disclosure has been described above with the aid offunctional building blocks illustrating the implementation of specifiedfunctions and relationships thereof. The boundaries of these functionalbuilding blocks have been arbitrarily defined herein for the convenienceof the description. Alternate boundaries can be defined so long as thespecified functions and relationships thereof are appropriatelyperformed.

The foregoing description of the specific embodiments will so fullyreveal the general nature of the disclosure that others can, by applyingknowledge within the skill of the art, readily modify and/or adapt forvarious applications such specific embodiments, without undueexperimentation, without departing from the general concept of thepresent disclosure. Therefore, such adaptations and modifications areintended to be within the meaning and range of equivalents of thedisclosed embodiments, based on the teaching and guidance presentedherein. It is to be understood that the phraseology or terminologyherein is for the purpose of description and not of limitation, suchthat the terminology or phraseology of the present specification is tobe interpreted by the skilled artisan in light of the teachings andguidance.

References in the specification to “one embodiment,” “an embodiment,”“an example embodiment,” “some embodiments,” etc., indicate that theembodiment described may include a particular feature, structure, orcharacteristic, but every embodiment may not necessarily include theparticular feature, structure, or characteristic. Moreover, such phrasesare not necessarily referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to affect such feature, structure,or characteristic in connection with other embodiments whether or notexplicitly described.

The breadth and scope of the present disclosure should not be limited byany of the above-described exemplary embodiments, but should be definedonly in accordance with the following claims and their equivalents.

1-20. (canceled)
 21. A modular system for blow molding a container, thesystem comprising: a first 3D printed mold portion; a second 3D printedmold portion; a 3D printed base mold portion; and a shell removablycoupled to the first 3D printed mold portion, the second 3D printed moldportion, and the 3D printed base mold portion, wherein the first 3Dprinted mold portion, the second 3D printed mold portion, and the 3Dprinted base mold portion together define a blow mold cavity when thefirst 3D printed mold portion, the second 3D printed mold portion, andthe 3D printed base portion are coupled to the shell, and wherein thefirst 3D printed mold portion, the second 3D printed mold portion, andthe 3D printed base mold portion are made of metal.
 22. The system ofclaim 21, wherein the first 3D printed mold portion and the second 3Dprinted mold portion each comprise at least one conformal coolingchannel.
 23. The system of claim 21, wherein the first 3D printed moldportion, the second 3D printed mold portion, and the 3D printed basemold portion each have a life cycle of at least 5000 containers.
 24. Thesystem of claim 23, wherein the life cycle is at least 100,000containers.
 25. The system of claim 21, wherein the first 3D printedmold portion, the second 3D printed mold portion, and the 3D printedbase mold portion are isotropic.
 26. The system of claim 21, wherein theshell comprises a first shell portion and a second shell portionconfigured to couple to the first shell portion, wherein the first 3Dprinted mold portion is removably coupled to the first shell portion,wherein the second 3D printed mold portion is removably coupled to thesecond shell portion, and wherein the 3D printed base mold portion isremovably coupled to the first shell portion and the second shellportion.
 27. An interchangeable mold for blow molding a container, themold comprising: a first 3D printed mold portion; a second 3D printedmold portion; and a 3D printed base mold portion, wherein the first 3Dprinted mold portion, the second 3D printed mold portion, and the 3Dprinted base mold portion are configured to together define a blow moldcavity, wherein the first 3D printed mold portion, the second 3D printedmold portion, and the 3D printed base mold portion are each compatiblewith a blow mold system, and wherein the first 3D printed mold portion,the second 3D printed mold portion, and the 3D printed base mold portionare isotropic.
 28. The mold of claim 27, wherein the first 3D printedmold portion and the second 3D printed mold portion each comprise atleast one cooling channel.
 29. The mold of claim 28, wherein the atleast one cooling channel is a conformal cooling channel.
 30. The moldof claim 27, wherein the first 3D printed mold portion, the second 3Dprinted mold portion, and the 3D printed base mold portion are eachcompatible with a shell for a blow mold system.
 31. The mold of claim30, wherein the shell comprises a first shell portion configured toengage with the first 3D printed mold portion and a second shell portionconfigured to engage with the second 3D printed mold portion.
 32. Themold of claim 31, wherein the first shell portion and the second shellportion are each configured to engage with the blow mold system to formblow-molded containers within the blow mold cavity.
 33. The mold ofclaim 27, wherein the first 3D printed mold portion, the second 3Dprinted mold portion, and the 3D printed base mold portion are made ofmetal.
 34. The mold of claim 27, wherein the first 3D printed moldportion, the second 3D printed mold portion, and the 3D printed basemold portion are made of material having a tensile strength of at least50 MPa
 35. A method of making a modular blow mold system, the methodcomprising: 3D printing a first mold portion, a second mold portion, anda base mold portion; coupling the first mold portion to a first shell toform a first half; coupling the second mold portion to a second shell toform a second half; coupling the base mold portion to a base shell toform a base; and coupling the first half, the second half, and the base,such that the first mold portion, the second mold portion, and the basemold portion together define a blow mold cavity for blow molding acontainer.
 36. The method of claim 35, wherein the 3D printing stepcomprises forming at least one cooling channel in the first mold portionand the second mold portion.
 37. The method of claim 36, wherein thecooling channel is a conformal cooling channel.
 38. The method of claim35, wherein the 3D printing step comprises 3D printing using a metal.39. The method of claim 35, wherein the first mold portion, the secondmold portion, and the base mold portion each have a life cycle of atleast 5000 containers.
 40. The method of claim 39, wherein the firstmold portion, the second mold portion, and the base mold portion eachhave a life cycle of at least 100,000 containers.